Process and apparatus for casting furnace bosh plates



Jan. 5 1926.

J. SMITH PROCESS AND APPARATUS FOR CASTING FURNACE BOSH PLATES 2Sheets-Sheet 1 Filed Jan. 29, 192 5 7 IN ENT'OR z c 1,568,096 J. SMITHPROCESS AND APPARATUS FOR CASTING FURNACE BOSH PLATES 2 Sheets-Sheet 2Filed Jan. 29, 1925 Jan. 5, 1926.

INVENTOR of the casting forms the nose of the plate Patented Jan. 5,1926.

[UNITED sra'rssv PATENT OFFICE.

JAMES SMITH, DECEASED, LATE OF DORMONT BOROUGH, PENNSYLVANIA; BY ISA-BELLA K. SMITH, ADMINISTRATRIX,

or DORMONT BOROUGH; PENNSYLVANIA,

ASSIGNOB TO ISABELLA K. SMITH, OF DORMONT, PENNSYLVANIA,

PROCESS AND AFPARATUS FOR CASTING FURNACE BOSE PLATES.

Application filed January To all whom it may concern;

Be it known that JAMES SMITH, deceased, late a citizen of the UnitedStates of America, and a resident ofthe borough of Dormont, in thecounty ofAllegheny and State of Pennsylvania, did invent a new andImproved Process andAp aratus for Casting Furnace Bosh Plates, 0 whichthe following is a specification. I I

The invention consists in a new and improved process and apparatus forcasting ofurnace bosh-plates' inan upright posit and without embeddedanchors; E

When, as hasheen the common. practice, bosh-platesare cast in ahorizontal position,

the horizontally disposed coremustf besupported in place by. means ofmetal anchors or chaplets which remain embedded, in, the casting andweaken. the same, frequently re-.- snlting in leaks or ruptures.

In Letters Patent of the'Uni'ted States, No. 1,438,271, issued onDecember 12, 1922, to the said James Smith, nowdeceased, a process andapparatus are disclosed for easting. bosh-plates in a vertical positionbutwith the nose of the plate at the top and its buttlat the bottom, thecore being supported from below'by; a sand base. The result is that thebest portion of the castin and the purest metal is in the butt of t eplate, while; its nose, whichis to be exposed to the greatest heat andwear, is formed of the poorest portion of the casting.

In the improved process herein described, the bosh-plates are cast in a*vertical position, but with their noses down, so that the purest metaland therefore the best portion while thepoorer metal goes to form thebutt.

Herein is disclosed new and improved apparatus whereby the new andimproved process may be successfully and commercially worked.

In the accompanying drawings, which are however merely intended toillustrate the principles of the invention without 1imiting the scopethereof to the structures shown, Fig. 1 is a vertical section takenalong the line II in Fig. 2 showing the mold and core assembled in theflask ready for pouring; Fig. 2 isa section along the line II II inFig.1,-also showing the pouring sprue; Fig. 3 is .an enlarged detail ofparts shown also ;in Fig. 1; Fig: 4 is a plan ion 2a,' -;1925. SerialNo. 5,658.

view of the core-box used totorm the sand core; Fig. 5 is a verticalsection illustrating the operation of forming the cheek-mold inaninverted position, showing the cheek, the

pattern and the sprue pattern assembled on cheek and drag, with theircontents, reverted "on...the bottom board and the follow board gremoved;Fig. 8 shows the cope superimposed on the cheek for the step of formingthe cope-mold; Fig. 9 shows the cope and cope-mold lifted off the cheekand cheekmold and set aside on trestles; Fig. 10 shows thecheek-moldlifted oil the dragmold and ,set on trestlesand the sand core set downinto the cheek-mold; Fig. 11' is a similar view with the cope mold inplace .on the cheek mold; Fig. 12 is a top plan view ofthe drag-moldshowing-the pouring gates'which connect with the lower end of the sprue;Fig. 13 is a horizontal sec- .tion taken along the line XIIL-XIII inFig. 11,- and Fig. 14 is a perspective of a conventional type ofbosh-plate which is shown for the sake of clearness in description.

The molding flask, which is'shown in Fig. 1 assembled ready for pouring,is comprised ofthe drag-A containingthe drag-mold A thecheek Bcontaining'the cheek-mold B,

and the cope C containing the cope-mold C.

D represents the sand core suspended from above from the cheek-mold. Erepresents the sprue which connects at its lower end with the horizontalates F formed in the top of the drag-mol and connected to the as bestshown in Fig. 12.

mold cavity at its opposite narrower sides,

The drag, cheek and cope. are detachably i connected together by thepins 1 which engage the. pierced ears 2. When the mold is ready forpouringthe entire flask'is clamped together in the usual manner.

The core D is suspended in place by the cross plates 3 whose ends reston the top of the cheek-mold and whose centers are provided withcircular holes in which are fixedthelengths of. pipes 4 held in place bythe upper and lower lock nuts 5. The under surface of the cope mold isprovided with suitable recesses 6 to provide clearance for the plates 3and the upper ends of the'pipes 4:. The lower ends of the pipes 4:extend down into and are embedded in the sand of sand of the core andits exposed portion being wrapped with asbestos tape 7 to prevent themetal adhering thereto. The under surface of the co e-mold is recessedto give clearance for tl ie upper end of the pipe 8. The wrapped portionof the pipe forms the central water port 8 of the finished boshplate, asshown in Fig. 14.

The embedded ends of the pipes 4 and 8 are perforated, as shown in Fig.3, to provide for the escape of the gases from the sand core, and thecope-mold .is provided with vent passages 9 connecting the upper ends ofthe pipes 4 and 8 to atmosphere to carry off said gases. 10 representswires extending down through said pipes and embedded in the sand of thecore to reinforce the latter, said wires being bent substantial- -ly asshown. Other wires 11 are also embedded in the core intersecting thecavities in which are formed the cross partitions of the bosh-plate. Theintersecting or adjacent portions of said wires may be tied together bylight wire which may be easily broken when the wires 10 are withdrawnfrom the cast plate.

The cope-mold has embedded in its lower surface two hard sand blocks Gwhich are provided with the substantially inverted U- shaped passages 12whose ends are open to receive the molten metal to form the handles 12of the bosh-plate, as shown in Fig. 14. The tops of said passages 12 areconnected by riser passages 13 with atmosphere, so that metal maycompl'etely'fillthe pas.- sages 12 to form the handles 12, and may riseup into view to indicate that the mold has been filled. Also dross andimpurities may thus escape through said risers.

14 represents temporary spacers, preferably formed by bending up a stripof sheet metal to substantially M-shape and inserting them at eitherside of the core between it and the cheek-mold near the lower end of thelatter. These spacers serve to properly center the core and hold it inposition, thus insuring walls of uniform thickness for the bosh-plate.These spacers are formed of metal which will melt when reached b andimmersed in the molten metal, and w iich will become amalgamated withthe metal of the plate without impairing-its quality. Thus, said spacersmay be made of thin sheet cooper.

The upper end of the sprue E is provided wlth a pouring cup 15. Risercups 15 are also placed at the upper ends of the riserpassages 13.

The metal is poured down through the sprue E and passes horizontallythrough the gates F into the mold cavity, first filling the lowerportion of. the cavity and thus formmg; the nose of the plate, and thenflowing upwardly, melting and amalgamating with it the temporary spacers14. When the metal comes to the surface through the riser passages 13,it indicates that the mold is full. l/Vhen the metal has set thebosh-plate is removed from the mold and the pipes 4 and 8, and the wires10 removed, the sand quickly and completely I removed from the interiorof the plate, the

metal which has hardened in the gates and risers cut off, and the ports4 and 8 are threaded for pipe connections.

It is evident that the best portion of the casting forms the nose of thelate where the greatest heat is to be resiste This has been impossibleof accomplishment by any previous method of casting bosh lates.

There is a decided advantage in introducing the molten metalhorizontally at the ends of the core instead of at the sides of thelatter. The core is much less likely to be displaced by this method ofintroducing the metal into the mold cavity. When the incoming metalimpinges against the extended sides of the core it is almost impossibleto prevent lateral shifting of the latter unless permanent supports,such as anchors or chaplets are used. Again, the introduction of themetal at the ends of the core insures a better distribution and equalflow of the metal.

There is a further advantage in introducing the metal at a level abovethe bottom or nose of the mold cavity. As the metal first fills up theportion of the mold cavity contained in the drag, it acts as a means forholding the core in its proper alinement, due to the upward rise of themetal, and when the rising level of the metal reaches and engulfs thetemporary spacers, the latter have served their purpose and are meltedby and amalgamated with the poured metal.

The following is the method of preparing and assembling the mold forcasting.

The core D is formed by ramming core sand into the core box D which isintegral with the board H. The box is provided with a nose wall 16, sidewalls 17 and butt wall 18, the side walls preferably diverging t0.

bosh-plate as shown in dotted lines in Fig. 14:. It wlll be understoodthat the parti- -tions 19 may be of any suitable character and pendingupon the particular design of boshplate which is to be cast.

The butt wall 18 of the core box is pro aided with end channels 20 andan intermediate channel 20* to receive thecore pipes 4 and 8. Thechannels 20 are shallower at their outer extremity, as indicated by theshoulder 20"., and, after a bottom layer of sand is placed in the box,the wrapped pipes t are laid therein with their lower lock nuts 5bearingoutwardly against said shoulders the inner and deeper portions ofthe channels; p

the=drag "and. all clampedithereto, and: the

providing room for the lower lock nuts and the asbestos wrapping 7, thusproviding:- convenient means for properly positioning the pipes 4 in thecore box.i The wrapped pipe 8 is also positioned in the intermediate Thewires '10 are placed in po-- channel sition with their outer endsextending through the pipes 4 and 8. The interior wires 11 are alsoplaced in position. The partitions 19 are apertured as shown to ac-'r-ommodate the-wires.

The core box is now filled with sand and rammed. The sand is then struckoff flush with the iopofthe core box anda core plate put in placeand'clamped tothe box, and the whole inverted. The clamps are thenremoved and the box rapped to free thecore and the box lifted off. The;core is then sprayed'and baked. v

The cheek B is inverted and placed on the' follow board I and thepattern J mounted thereon. The sprue form E is then stepped into asocket in the follow board; The sand is now filled in and rammed, thusforming the cheek-mold B.- This step is illustrated in Fig. 5. Referringnow to Fig. 6, the drag A is now inverted and placed on the cheek B andthe sand filled in and rammed,

parting sand being used to separate the molds. The bottom board K is nowplaced on the drag A, and the parts are clamped together and the wholereverted into the position shown in Fig. 7 and the follow board removed.

The cope C is placed on the cheek B, as

shown in Fig. 8. The sprue pattern E is drawn upward until its top islevel with the top of the cope. The previously prepared sand blocks Gare placed inposition on the top of the pattern J. The print-forms '3and 8 are positioned on the pattern J to form the recesses to receivethe plates 3 and the upper ends of the pipes 4: and 8. A parting is madeand the, sand is now filled in and rammed to form the cope-mold C.

The cope and its mold is then removed.

ositioned in any desired manner de and the pattern J is'withdrawn, andthe cheek and its mpld lifted from the drag and set on trestles, asshown in- Fig. '10. The plates 3 are. now placed in position on thepipes 4 and the upper lock nuts 5 are put in place. The core D is thenplaced down in thecheek' mold, as shown in Fig. 10, being supported fromabove by means of the crossplates 3 'which span the cheek mold as shown.The temporary spacers 14 are then inserted up between the core I) andthe cheek mold B. The gates Fare cut in the top surface of the drag moldA, as shown in Fig. 12. The'cope G and its mold C are replaced onthezcheek' Band its mold B, as shown in Fig .--1'1-. szTherventpassages9 and the .rise'r. passages '13 have. been: previously formedtheacope-mold Q".' 1 I Y 'mold': is ready for pou'ring.

molten metal first flows downwardly from 3 the admission level to formthe nose of the plate which metal 'in' setting anchors the core inposition, and the subsequently admitted metal flows upwardly within thecavity to form the remainder of the plate.

2. The process of casting furnace b'oshplates, nose downwardly and in avertically disposed position in a moldwherein-the core issuspended fromabove, which consistsin admitting the metal into; the mold cavitysurrounding the core at theoppositenarrower sidesof the core and at alevelabove but near the lower endof the core, so that the metal firstflows downwardly from the admission level to form the nose of the platewhich metal in setting anchors the core in position, and thesubsequently admitted metal flows "upwardly within the cavity toform theremainder of the plate.

3. The process of casting furnace boshplates,-nose downwardly and in avertically disposed position in 'a mold wherein the core is suspendedfrom above, which consists in interposin between the broader sides ofthecore and tie adjacent mold walls temporary spacers, and admitting themetal atthe narrower sides of the core at'a level near but above thelower end of th core so thatthe molten metal first admitted flowsdownwardly in the cavity surrounding the core plate, nose downwardly, ina vertically disposed position, in a mold containing acoreinterposingbetween the broader sides of the core and the adjacent mold wallstemporary spacers, and admitting the meta'lat the narrower sides of thecore at a level near but above th lower end of the core sothat'themolten metal first admitted flows down wardly in the cavity surroundingthe core to form the nose of the plate and said metal in setting anchorsthe core in position and the subsequently admitted metal flows upwardlywithin the mold cavity and forms ,4

the remainder of the late, the spacers being of suitable material sothat they are melted by the rising metal and become amalgamated in theplate.

5. The process of casting a furnace boshsuspended from above, whichconsists in interposing between the sides of the core and the mold wallstemporary spacers meltable by the molten metal, and introducing themolten metal at both narrower sides of the core.

6. The process of casting'a furnace boshplate, nose downwardly, in avertically disposed position, in a mold containing acore suspended fromabove, which consists in inter-posing between the sides of the core andthe mold walls temporary spacers meltable by the molten metal,introducing the molten metal at both narrower sides of the core, and alevel slightly above the lower extremity of the core whereby the nose ofthe plate is first cast and the metal in setting forms a centeringsupport for the core.

7. The process of casting a furnace boshplate, nose downwardly, in avertically disposed position, in a mold containing a core suspended fromabove, which consists in introducing the molten metal into the mold atthe narrower sides of the core and slightly above the lower extremity ofthe latter, whereby the nose of the bosh-plate is first formed and themetal in setting forms a centering support for the core.

In means for casting furnace-bosh plates, nose downwardly and in avertically disposed position, th combination of a mold, a core suspendedfrom above in the mold cavity, and pouring gates leading into the moldcavity opposite to both the narrower sides of the core. I i

9. In means for casting furnace-bosh plates, nose downwardly and in avertically disposed position, the combination of a mold, a coresuspended from above in the mold cavity, and pouring gates leading intothe mold cavity opposite to both the narsides of the core, and temporaryspacers interposed between the broader sides of the core and the wallsof the mold cavity.

11. In means for casting furnace-bosh plates, nose downwardly and in avertically dis osed position, the combination of a mo (1, a coresuspended from above in the mold cavity, pouring gates leading into themold cavity opposite to both the narrower H sides of the core, andtemporary spacers in terposed between the broader sides of the core andthe walls of the mold cavity, said spacers being of suitable material soas to be melted by and amalgamated with the molten metal.

12. In means for casting anchorless boshplates in a vertical-positioncomprising a mold, a core suspended from above in said mold, and meansfor introducing the molten metal into the lower portion of the mold at alevel slightly above the lower extremity of the core and at bothnarrower sides thereof.

13. In means for casting anchorless boshplates in a vertical positioncomprising a mold, a core suspended from above in-said 'mold, means forintroducing the molten metal into the lower portion of the mold at alevel slightly above the lower extremity of the core and at bothnarrower sides thereof, and temporary spacers interposed be tween thesides of the core and the walls of the mold above the level of theentrance of the molten metal.

14. In means for casting anchorless boshplates in a vertical positioncomprising a mold, a core suspended from above in said mold, means forintroducing. the molten metal into the lower portion of the mold at alevel slightly above the lower extremity of the core and at bothnarrower sides thereof, and-temporary spacers interposed between thesides of the core and the walls of the mold above the level of theentrance of the molten metal, said spacers being of material adapted tobe melted by the metal and to be amalgamated therewith.

15. In means for casting furnace boshplates in a vertically disposedposition and nose-downwardly comprising a mold having a cavitycorresponding to the outer conformation of the bosh-plate to be formed,a core suspended from above within said cavity, and gates for theadmission of metal opening into the lower portion of said cavity gates.

and above the lower extremity of said core, said gate-s being formed inthe two narrower vertical walls of said cavity adjacent to the narrowersides of said core.

y 16. In means for casting furnace bosh plates in a vertically disposedposition and nose-downwardly comprising a mold having a cavitycorresponding to the outer eonformation of the bosh-plateto be formed, acore suspended from above within said cavity, gates for the admission ofmetal OPGIllIlglIltO the lower portion of said cavity and above thelower extremity of said core, said gates being formed in the twonarrower 15 vertical walls of said cavity adjacentto the narrower sidesof said core, and temporary spacers lnterposed between the core and thewalls of the cavity above the level of the 17. In means for castingfurnace boshplates in a vertically disposed position and nose-downwardlycomprising a mold having a cavity corresponding to the outerconformation of the bosl1plate to be formed, a core suspended from abovewithin said cavity, gates for the admission of metal open ng into thelower portion of said cavity and above the lower extremity of said core,said gates being formed in the two narrower vertical walls of saidcavity adjacent to the narrower sides of said core, and temporaryspacers interposed between t'liecore and the *walls of the cavity abovethe level of the gates, said spacers being composed of material which ismelted and incorporated in the molten metal as the latter engulfs saidspacers.

Signed at of January, 1925.

' ISABELLA K. SMITH, Arlmimlstrat'r im of the Estate of Jams Smith,deceased.

Pittsburgh, Pa., this 17th day i

